JP2023550718A - In-line lamination process for producing decorative thermoplastic composite panels - Google Patents

Abstract

An in-line system and method for manufacturing lightweight reinforced thermoplastic composite panels is described. In-line systems and methods can be used to produce composite panels with smoother surfaces and enhanced properties in an automated manner. The manufactured composite panel can include a decorative layer that can provide an overall smoother panel surface compared to a composite panel lacking the decorative layer.

Description

priority claim

This application is filed in U.S. Patent Application No. 63/112,914, filed on November 12, 2020, U.S. Patent Application No. 63/145,073, filed on February 3, 2021, and Each claims priority and benefit from U.S. patent application Ser. No. 63/188,358, filed on May 13th. The entire disclosure of each of these applications is incorporated herein by reference.

Technical field

Certain configurations described herein relate to in-line lamination processes by which decorative panels can be manufactured. In some examples, decorative panels can be used for recreational vehicles or architectural applications.

background

Manufacturing decorative panels can be time consuming and tedious. Different components of a panel are often manufactured in different processes or at different locations.

overview

Certain aspects, configurations, embodiments, and examples of in-line processes that can be used to manufacture decorative panels that can be used in recreational vehicles or architectural applications are described.

In one aspect, a process for manufacturing thermoplastic composite articles using an in-line system is described. In certain configurations, the in-line process involves combining reinforcing materials and thermoplastic materials in an aqueous solution. The in-line process can also include placing an aqueous solution of the reinforcing material and thermoplastic material on the moving support. The in-line process can also include removing water from an aqueous solution disposed on a moving support to form a web that includes an open cell structure formed from reinforcing material and a thermoplastic material. The in-line process can also include drying the web on the moving support to provide a porous core layer. The in-line process can also include heating the dry porous core layer on the moving support to melt the thermoplastic material of the heated porous core layer. The in-line process can also include disposing a first skin layer on the first surface of the heated porous core layer on the moving support. The in-line process can also include disposing a second skin layer on the second surface of the heated porous core layer on the moving support. The in-line process also applies pressure to a heated porous core layer including a first skin layer disposed on a moving support and a second skin layer disposed on a moving support to provide a thermoplastic composite article. can include adding.

In certain embodiments, the porous core layer is heated at a first temperature above the melting point of the thermoplastic material and below the melting point of the reinforcing material. In some embodiments, the in-line process can include adding the foam to an aqueous solution mixed with reinforcing material and thermoplastic material. In other examples, the in-line process can include adding a lofting agent to an aqueous solution of a mixed reinforcing material and thermoplastic material. In an additional example, the inline process can include configuring the first skin layer as a scrim. In some embodiments, the in-line process can include configuring the second skin layer as a patterned layer. In specific examples, patterned layer patterns include woodgrain pattern, marble pattern, tile pattern, random pattern, whirlpool pattern, herringbone pattern, brick pattern, offset staggered brick pattern, offset pattern, lattice pattern, stacked vertical pattern, French pattern, a basket weave pattern, a diamond pattern, or a chevron pattern. In other embodiments, the thermoplastic material includes polyolefin and the reinforcing material includes inorganic fibers.

In some examples, the surface roughness (Ra) of the thermoplastic composite article is less than 3 microns in the machine and transverse directions as measured by a stylus profilometer according to ISO 4287:1997. In other examples, the surface roughness (Ra) of the thermoplastic composite article is less than 2 microns in the machine and transverse directions as measured by a stylus profilometer according to ISO 4287:1997.

In some embodiments, the first skin layer is disposed on the heated porous core layer without the use of an adhesive between the first skin layer and the heated porous core layer. Ru. In certain embodiments, the in-line process includes disposing an adhesive on the second surface of the heated porous core layer prior to disposing the second skin layer on the second surface. In some embodiments, the adhesive comprises a polyolefin or polyurethane. In a particular example, the in-line process includes cutting a groove in the first end of the thermoplastic composite panel. In other examples, the in-line process includes cutting a tongue into the second end of the thermoplastic composite panel.

In some embodiments, the in-line process includes heating the porous material before disposing the first skin layer on the first surface and before disposing the second skin layer on the second surface. including consolidating the core layer.

In certain examples, the in-line process includes heating the thermoplastic composite article after consolidating the thermoplastic composite article to increase the overall thickness of the thermoplastic composite article.

In an additional example, the in-line process includes printing a pattern on the second skin layer prior to disposing the second skin layer on the second surface of the heated porous core layer.

In other embodiments, the in-line process includes printing a pattern on the second skin layer after disposing the second skin layer on the second surface of the heated porous core layer.

In other embodiments, the in-line process includes compressing side edges of the heated porous core layer, and the compressed side edges of the heated porous core layer are It has a thickness that is less than the thickness of the central region.

In another aspect, an in-line system configured to manufacture thermoplastic composite articles is provided. In certain embodiments, the in-line system includes a fluid reservoir configured to receive an aqueous solution, a thermoplastic material, and a reinforcing material, the fluid reservoir configured to mix the thermoplastic material and the reinforcing material in the aqueous solution, and to mix the thermoplastic material and the reinforcing material in the aqueous solution. of thermoplastic material and reinforcing material. In other embodiments, the in-line system includes a moving support fluidly coupled to a fluid reservoir and configured to receive a uniform dispersion from the fluid reservoir and maintain the uniform dispersion on the moving support. In some examples, the in-line system was configured to remove water from the uniform dispersion on the moving support to provide a web containing an open cell structure formed from the reinforcing material and the thermoplastic material. Equipped with a pressure device. In certain examples, the in-line system includes an apparatus configured to dry and heat the web on the moving support to provide a porous core layer on the moving support. Separate drying and heating equipment can also be used if desired. In other examples, the in-line system includes a heating device configured to heat the porous core layer on the moving support to melt the thermoplastic material of the porous core layer. In an additional example, the in-line system includes a first supply device configured to receive a first skin material, the first supply device moving and supporting the first skin material as a first skin layer. the first surface of the porous core layer on the body. In other embodiments, the in-line system includes a second supply device configured to receive a second skin material, the second supply device transferring the second skin material as a second skin layer. The porous core layer is configured to be provided on a second surface of the porous core layer on the support. In an additional configuration, the in-line system deploys the heated porous core layer by applying pressure to the heated porous core layer, the disposed first skin layer, and the disposed second skin layer. a compaction device configured to compact the disposed first skin layer and the disposed second skin layer to provide a substantially planar thermoplastic composite article.

In certain embodiments, the first supply device is configured to receive a roll of first skin material. In other embodiments, the second supply device is configured to receive a roll of second skin material. In an additional embodiment, the in-line system further comprises an apparatus configured to cut the thermoplastic composite article into individual sheets as the thermoplastic composite article exits the moving support. In some examples, the in-line system includes a second heating device positioned after the compaction device, the second heating device heating the thermoplastic composite article to form the compacted thermoplastic composite. Configured to increase the overall thickness of the material. In other configurations, the in-line system includes a sprayer fluidly coupled to the fluid reservoir, the sprayer configured to spray a uniform dispersion onto the moving support. In some embodiments, the in-line system applies a second skin layer on the second surface of the heated porous core layer prior to disposing the second skin layer on the second surface of the heated porous core layer. An adhesive reservoir configured to dispose an adhesive is provided.

In certain configurations, the in-line system includes a printer configured to print a pattern on the second skin layer after the second skin layer is disposed on the second surface of the heated porous core layer. Equipped with. In other embodiments, the in-line system is configured to print the pattern on the second skin material before the second skin layer is disposed on the second surface of the heated porous core layer. Equipped with a printer. In some embodiments, the in-line system includes a processor configured to control movement of the moving support.

In another aspect, a recreational vehicle (RV) wall includes a porous core layer, a first skin layer on a first surface of the porous core layer, and a patterned layer on a second surface of the porous core layer. a first laminated lightweight reinforced thermoplastic composite article comprising: a second skin layer; In some examples, the RV wall includes a foam layer bonded to a first laminated lightweight reinforced thermoplastic composite article at a first surface of the foam layer, the foam layer being bonded to a first laminated lightweight reinforced thermoplastic composite article; The second skin layer is bonded to the first laminated lightweight reinforced thermoplastic composite article through the first skin layer of the reinforced thermoplastic composite article such that the patterned second skin layer is bonded to the inside wall of the recreational vehicle. Exists on the surface. In other embodiments, the RV wall includes a support structure bonded to a second surface of the foam layer at a first surface of the support structure. In a further example, the RV wall includes a second laminated lightweight reinforced thermoplastic composite article coupled to a second surface of the support structure, the second laminated lightweight reinforced thermoplastic composite article having a porous core layer. a first skin layer on a first surface of the porous core layer; and a second skin layer on a second surface of the porous core layer. In some embodiments, the RV wall includes an exterior panel bonded to a second laminated lightweight reinforced thermoplastic composite article. In some examples, the exterior panel includes fiberglass or aluminum. In other examples, the support structure includes tubes or networks.

In certain embodiments, the patterned second skin layer includes a woodgrain pattern, a marble pattern, a tile pattern, a random pattern, a whirligig pattern, a herringbone pattern, a brick pattern, an offset staggered brick pattern, an offset pattern, a lattice pattern, including one or more of a stacked vertical pattern, a French pattern, a basket weave pattern, a diamond pattern, or a chevron pattern. In some embodiments, the first skin layer of the first laminated lightweight reinforced thermoplastic composite article comprises a scrim. In other embodiments, the porous core layer of the first laminated lightweight reinforced thermoplastic composite article includes a web that includes an open cell structure formed from reinforcing fibers held together by a thermoplastic material. In other configurations, the porous core layer of the second laminated lightweight reinforced thermoplastic composite article includes a web that includes an open cell structure formed from reinforcing fibers held together by a thermoplastic material. In certain examples, the thermoplastic material in each porous core layer independently comprises a polyolefin. In some embodiments, the reinforcing material of each porous core layer includes glass fibers. In other embodiments, the thermoplastic material in each porous core layer is polypropylene.

In another aspect, a recreational vehicle includes a roof, a sidewall coupled to the roof, and a floor coupled to the sidewall to provide an interior space within the recreational vehicle, and at least one of the sidewalls has a main body. The recreational vehicle wall panel described in the specification is provided. In some embodiments, the recreational vehicle includes wheels to allow the recreational vehicle to be towed or driven.

Additional aspects, configurations, embodiments and examples are described below.

A brief overview of some of the drawings

Certain specific examples are described below to facilitate a better understanding of the technology described herein with reference to the accompanying drawings.

1 is a simplified diagram illustrating a sidewall of a recreational vehicle, according to some embodiments; FIG. FIG. 2 is a block diagram illustrating certain steps of an inline process that may be used, according to some embodiments. FIG. 3 illustrates certain components that can be used to add materials to a mixing tank, according to certain examples. FIG. 2 is an illustration of a moving support according to some embodiments. FIG. 2 is an illustration of a moving support according to some embodiments. FIG. 2 illustrates a drying apparatus according to certain embodiments. FIG. 2 illustrates a drying apparatus according to certain embodiments. FIG. 2 illustrates a drying apparatus according to certain embodiments. FIG. 3 illustrates the application of a skin layer to a core layer, according to certain embodiments. FIG. 3 illustrates the application of a skin layer to a core layer, according to certain embodiments. FIG. 3 illustrates an adhesive layer reservoir that can be used to apply adhesive to a surface of a core layer, according to some examples. FIG. 3 illustrates a roller that can be used in an in-line process, according to some examples. FIG. 3 illustrates a roller that can be used in an in-line process, according to some examples. FIG. 3 illustrates a cutting device that can be used to cut a moving composite article into individual composite articles, according to certain embodiments. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 3 illustrates different patterns that may be present on a patterned skin layer, according to some examples. 1 is a diagram of a system that can be used to execute inline processes, according to certain embodiments. FIG. 1 is a diagram of a system that can be used to execute inline processes, according to certain embodiments. FIG. 1 is a diagram of a system that can be used to execute inline processes, according to certain embodiments. FIG. 1 is a diagram of a system that can be used to execute inline processes, according to certain embodiments. FIG. FIG. 2 is another diagram of a system that can be used to execute inline processes, according to certain embodiments. FIG. 2 is another diagram of a system that can be used to execute inline processes, according to certain embodiments. 1 is an illustration of a recreational vehicle (RV) wall according to some embodiments; FIG. 1 is an illustration of a recreational vehicle that can include an RV wall as described herein, according to some examples. FIG. This is a photo showing the wood grain pattern. This is a photograph showing a marble pattern. FIG. 3 illustrates a test specimen used in a flat tensile test, according to certain embodiments. FIG. 3 illustrates a test specimen used in a flat tensile test, according to certain embodiments. FIG. 3 is a diagram showing the peak load of a particular test piece. FIG. 3 is a diagram showing the bending slope of a particular test piece. The sound absorption test results of the test sample and reference sample are shown. The sound absorption test results of the test sample and reference sample are shown.

detailed description

It will be appreciated by those skilled in the art, given the benefit of this specification, that the different layers described herein are not necessarily shown to scale. It is not intended that any material be required in any one layer unless specifically indicated in the description associated with that particular configuration. The thickness, placement, and end use of decorative panels may vary.

In certain embodiments, the processes described herein can be used to manufacture decorative panels for use in architectural applications, vehicles such as recreational vehicles, and other applications. Recreational vehicles (RVs), including campers and towed vehicles, can incorporate lightweight glass fiber reinforced thermoplastic composite panels into sidewalls, ceilings, roof shingles, or flooring components to reduce weight. Compared to traditionally used wood composites, i.e. plywood, polymer composites are formaldehyde-free, have better durability, lower weight for fuel efficiency, improved acoustic performance, water resistance and It offers a wealth of benefits such as mold resistance and flame retardancy derived from the high degree of functional integration of the glass and thermoplastic matrix. In some configurations, reinforcing fibers, such as glass fibers, can advantageously add to the modulus of the resin matrix, providing enhanced properties with minimal weight increase. The performance of the resulting composite may depend, at least in part, on the core formulation (fiber/resin ratio), weight per unit area (areal density), panel application thickness, and functional skin material.

In certain embodiments, a decorative layer, sometimes referred to herein as a decor, can be used to cover/hide the porous, rough texture of the underlying material and provide a more natural material appearance. . For example, the cosmetic skin can be bonded to the underlying web or core layer in an on-line process and therefore generally cannot be separated from the composite core. The resulting composite article can exhibit strong tensile strength, eliminating problems with cosmetic skin//core delamination at interfaces between layers within the RV sidewall structure. Cosmetic skin materials can also improve the bending stiffness of the board, especially in the longitudinal direction. The patterned panels can also pass ASTM E84 Class A flame retardant classification.

In certain embodiments, lightweight reinforced thermoplastic (LWRT) composites may be used in RV sidewall and roof shingle applications. RV sidewall construction typically includes an exterior wall material, foam insulation (e.g., PET, EPS or honeycomb foam), and interior wall layers, all of which are laminated or glued together and then installed on the roof and floor to form the unit. Provides strength throughout. For example, referring to FIG. 1, a simplified diagram shows RV 100 and RV sidewall 110. An exploded view of the sidewall 110 shows a fiberglass sheath 112, an LWRT layer 114, a chassis 116, such as a metal cage or tubular structure, a foam 118, and another LWRT 120, typically on the interior surface of the RV. include. The LWRT 120 may include a cosmetic pattern on an interior surface of the RV that is visible to a person inside the RV. As discussed below, LWRT 120 can include a porous web in combination with a cosmetic skin and optionally additional skin layers. In traditional manufacturing methods, a decorative paper or vinyl film is applied off-line onto a substrate (typically plywood). However, in the past few years, concerns about formaldehyde emissions, the poor durability of plywood, and the high cost of offline lamination processes due to the use of polyurethane (PUR) adhesives to bond decorative materials to plywood have led to This has stimulated interest in developing products by in-line laminating decorative materials onto durable composite panels. In-line laminated decorative composite panels can provide similar or better high-quality surfaces, gloss, and color depending on the design/pattern compared to offline laminated plywood/decor panels.

In certain embodiments, an in-line process for manufacturing decorative panels includes a number of steps that are typically controlled in an automated manner using a processor or computer, as described in more detail below. can be included. The specifics of the process and the various materials used/manufactured by each step are illustrated by the block diagram of FIG. 2. The LWRT layer is prepared by combining a thermoplastic material (TP), such as a thermoplastic resin, and a reinforcing material (RM) to form a dispersion or mixture 202. This mixture can then be deposited onto a suitable moving support to provide a web 204 formed by reinforcing material and thermoplastic. The resulting web can include an open cell structure of reinforcing fibers held in place by a thermoplastic material. The resulting web can be heated and dried to soften or melt the thermoplastic resin and form porous core layer 206. One or more skin layers can then be applied to the surface of the formed and heated porous core layer. For example, a decorative layer can be applied to form the LWRT composite article 208. The resulting LWRT composite can be consolidated into a flat sheet 210 that can be used to form RV panels or other composite panels. For example, a flat sheet 210 on a moving support can be cut to provide individual LWRT composite articles 212. Various exemplary process conditions, steps and materials are described in more detail below.

As shown in FIG. 3, a thermoplastic material can be present in reservoir 302 and reinforcing fibers (or other reinforcing material) can be present in second reservoir 304. Each of the thermoplastic materials and reinforcing fibers can be metered, sprayed, or otherwise introduced into an aqueous solution in a mixing tank 306 containing water, liquid, or an aqueous solution. Optionally, foam or other additives (described below) may be present in the mixing tank 306. The thermoplastic material and reinforcing fibers can be mixed for a suitable time and at a suitable temperature to provide a substantially homogeneous aqueous dispersion of fibers and thermoplastic material. For example, the materials may be mixed at room temperature, such as about 25 degrees Celsius, or above or below room temperature by heating or cooling a mixing tank. In some embodiments, materials can be continuously added to the mixing tank 306 to continuously deposit the dispersion on the moving support, as described below. Although the exact mixing time may vary depending on the materials used, exemplary mixing times include from 10 seconds to about 10 minutes, and more specifically from about 30 seconds to about 5 minutes. However, as mentioned above, if materials are continuously added to the mixing tank 306, mixing will always occur. Mixing tank 306 may include a paddle mixer, impeller, or other device to facilitate mixing.

In certain embodiments, referring to FIG. 4A, the dispersion in mixing tank 306 can be sprayed, dripped, or otherwise deposited onto moving support 410. Although moving support 410 is shown as a single segment in the particular figures shown herein, moving support 410 can be divided into two or more individual segments if desired. . Mixing tank 306 can be fluidly coupled to a plurality of spray heads 402 that can spray the dispersion onto the surface of moving support 410 . As shown in FIG. 4B, the moving support 410 may be porous or include a mesh capable of receiving the dispersion. The exact deposition rate used may vary depending on the amount of material deposited per square meter. The moving support 410 can move continuously and at a constant speed to enable continuous spraying of the dispersion along the top surface of the moving support 410. The area of moving support 410 below the spray head can be heated, cooled, or present at room temperature during deposition of the dispersion. As discussed below, different regions of moving support 410 can have different temperatures. The exact dimensions of the moving support 410 may vary, but typically the moving support is about 4 feet wide and has between about 60 openings/inch square and about 80 openings/inch square. The mesh or pore size of the body 410 can be included. The mobile support 410 allows for receiving the dispersion and moving the received dispersion to additional locations or stations of the in-line system. At the end of the moving support 410, the formed LWRT articles can be cut and stacked. Moving support 410 allows continuous formation of LWRT articles. In certain embodiments, moving support 410 can be divided into two or more separate sections or segments. For example, a wet mat can be formed on the former belt and then transferred, eg manually or automatically, onto a separate dryer belt where it can be passed through an oven or other drying device.

In certain embodiments, referring to FIG. 5A, a moving support 410 containing a dispersion of thermoplastic material and reinforcing fibers can be moved to a drying device 510. Drying device 510 can provide heat and/or negative pressure (vacuum) to remove water from web 502 on the moving support, leaving reinforcing fibers and thermoplastic material on the moving support 510. This process can form a highly porous core layer 512 (see FIG. 5B) that includes an open cell structure formed from reinforcing fibers held in place by a thermoplastic material. Other materials may also be present within the core layer or sprayed onto the core layer 512, if desired. For example, the surface of the formed core layer 512 can be sprayed with adhesive from a reservoir. The exact temperature used to heat the web 502 and/or core layer 512 may vary, and desirably the temperature is above the melting point of the thermoplastic material and below the melting point of the reinforcing fibers. In some examples, the moving support 410 itself can be heated, while in other examples, the drying device 510 can include a heating element or be configured as an oven or other heating device. If desired, both the drying device 510 and the moving support 410 can provide heat to the web 502 on the moving support 410. In some cases, moving support 410 is a thermally conductive material that can retain heat from drying device 510 to help maintain core layer 512 in a softened form during application of skin layers or other materials. can include materials. In some examples, there may be a pressure device 520 separate from the drying device 510 (see FIG. 5C). For example, a vacuum can be applied to the web 502 to remove water from the web and leave behind the reinforcing material and thermoplastic material. Pressure device 520 is typically upstream of drying device 510 and is designed to remove at least 40% of the volume of water from web 502, and more specifically about 60% of the volume of water from web 502. ing. If desired, another pressure device (not shown) can be placed downstream of pressure device 520.

In certain embodiments, once the core layer 512 exits the drying device 510, one or more skin layers can be applied to the surface of the core layer in an automated manner. Referring to FIG. 6A, a diagram is shown in which a skin layer 610 is applied to the core layer 512 as it exits the moving support 410. For example, skin layer 610 may exist as a roll of skin layer material 605 that is unrolled and applied sequentially to one surface of core layer 512. As shown in FIG. 6B, a second skin layer 620 can be applied to the second surface of the core layer 512 from a second roll 615 that includes a second skin material. The skin layers 610, 620 can be applied at room temperature, even though the core layer 512 can still be heated, or otherwise reside on the moving support 410 above room temperature. Alternatively, rolls 605, 615 or skin layers 610, 620, or both, can be heated before being applied to the surface of core layer 512. Skin layers 610, 620 may generally be applied sequentially to form a thermoplastic composite article including core layer 512, first skin layer 610, and optionally second skin layer 620. Although not shown, additional skin layers can be applied over the skin layers 610, 620 using a similar process.

In some embodiments, it may be desirable to apply an adhesive layer over the core layer 512 before applying the skin layer 610 to the core layer 512. In such a case, an adhesive reservoir 720 (see FIG. 7) is present and can be used to spray adhesive onto the surface of the core layer 512 prior to application of the skin layer 610 so that the adhesive layer 722 It exists on the surface of the core layer 512. The exact adhesive used may be different from a thermoplastic adhesive, a thermoset adhesive or a combination thereof. Although not shown, an adhesive may also be applied to the opposite surface of the core layer 512 prior to applying the skin layer 620 to the core layer 512. Exemplary adhesives include polyolefin adhesives, polyurethane adhesives, and combinations thereof.

In certain embodiments, the resulting thermoplastic composite article can be consolidated by applying pressure to the surface of the composite article. For example, referring to FIG. 8A, a composite article can be passed between rollers 810, 812 to compress the composite article and strengthen the bond of skin layers 610, 620 to core layer 512. The exact distance or gap between rollers 810, 812 may vary depending on the desired pressure applied and the desired final thickness of the composite article. Generally, the overall thickness of the composite article decreases after passing through rollers 810, 812. Rollers 810, 812 can operate at room temperature, above room temperature, or below room temperature. Multiple sets of rollers 810, 812 may be present if desired. For example, referring to FIG. 8B, a second set of rollers 820, 822 is shown. The gaps between different roller sets may be different. For example, the first set of rollers 810, 812 may have a first gap that is smaller than the gap between rollers 820, 822. The gaps between the various rollers may be fixed or may vary. For example, it may be desirable to compress certain regions of a composite article more strongly so that these compressed regions have a smaller thickness. In some cases, the edges of the composite article can be more compressed such that the thickness at the side edges of the composite article is lower. There may be three, four or more roller sets as required. The rollers can optionally be placed in an oven or heating device to maintain the core layer in a softened form during consolidation of the composite article.

In certain embodiments, once the composite article is consolidated, the continuous sheet of consolidated composite article can be cut or shredded into individual sheets using cutting device 910 (see FIG. 9). can. The resulting individual composite articles can be stacked or palletized, such as on a pallet 915, for shipping, as shown in stack 920. The dimensions of the composite article in FIG. 9 are intentionally enlarged to show stacking, as composite articles tend to be stacked as individual thin sheets having a thickness of, for example, 1 mm to about 30 mm. The exact size of an individual composite article may vary from about 2 feet wide to about 8 feet wide and from about 4 feet long to about 16 feet long. In some embodiments, individual composite articles may be about 4 feet wide by about 8 feet long, thus having dimensions similar to plywood panels commonly used in recreational vehicles. .

In certain configurations, the core layer manufactured using an in-line process can include reinforcing fibers in combination with a thermoplastic resin. For example, the core layer can be formed from a random arrangement of reinforcing fibers held in place by a thermoplastic material. The core layer typically includes a significant amount of open cell structure such that there is void space within the layer. In some examples, the porous core layer is 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%. %, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90 %, 10-95%, 20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95 %, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95%, 70-80%, 70-90%, 70-95%, 80-90 %, 80-95%, or any porosity within these exemplary ranges.

In certain embodiments, the thermoplastic materials used to form the core layer described herein include polyolefins (e.g., one or more of polyethylene, polypropylene, etc.), polystyrene, acrylonitrile styrene, butadiene. , polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or with other polymeric materials. may include. Other suitable thermoplastics include polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ethers Ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystalline polymers, poly(1,4 phenylene) compounds marketed as PARMAX®, high temperature polycarbonates such as Bayer's APEC® PC, high temperature Includes, but is not limited to, nylon and silicone, and copolymers, alloys and blends of these materials with each other or with other polymeric materials. The thermoplastic material used to form the core layer can be used in powder form, resin form, rosin form, particulate form, fiber form or other suitable form. Exemplary thermoplastic materials in various forms are described herein, such as in US Patent Application Publication No. 20130244528 and US Patent Application Publication No. 20120065283. The exact amount of thermoplastic material present in the core layer may vary, with exemplary amounts being from about 20% to about 80% by weight, such as from 30 to 70% by weight, based on the total weight of the core layer. % or in the range of 35-65% by weight. It will be recognized by those skilled in the art that the weight percentages of all materials used in the core layer increase to 100 weight percent.

In other embodiments, the reinforcing fibers of the core layer include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, especially high modulus organic fibers, such as para- and meta-aramid fibers, nylon fibers, polyester fibers, fibers high melt flow index resins (e.g. 100g/10min MFI or higher) suitable for use as mineral fibers such as basalt, mineral wool (e.g. rock or slag wool), wollastonite, alumina-silica, or mixtures thereof; It can include metal fibers, metallized natural and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers can be chemically treated prior to use to provide desired functional groups or to impart other physical properties to the fiber, such as It can be chemically treated to react with the thermoplastic material, the lofting agent, or both. The fiber content in the core layer may independently be from about 20% to about 90% of the weight of the core layer, and more particularly from about 30% to about 70% of the weight of the core layer. The particular size and/or orientation of the fibers used may depend, at least in part, on the thermoplastic material used and/or the desired properties of the core layer. In one non-limiting example, the fibers dispersed within the thermoplastic material and optionally other additives to provide the core layer are generally greater than about 5 microns, more specifically about 5 microns. may have a diameter of ~22 microns, and a length of about 5 mm to about 200 mm; more specifically, the fiber diameter may be about 2 microns to about 22 microns, and the fiber length is about 5 mm. ~about 75 mm.

In certain embodiments, other additives may also be present in the mixture containing the thermoplastic resin and reinforcing fibers. For example, lofting agents, flame retardants, colorants, smoke suppressants, surfactants, foams or other materials may be present. In some examples, the core layer may be a substantially halogen-free or halogen-free core layer to meet restrictive hazardous material requirements for a particular application. In other examples, the core layer comprises a halogenated flame retardant, e.g., a halogenated flame retardant comprising one or more of F, Cl, Br, I, and At, or a compound containing such a halogen, e.g., tetra Bromobisphenol-A polycarbonates or monohalo-, dihalo-, trihalo- or tetrahalo-polycarbonates may be included. In some cases, the thermoplastic material used in the core layer may include one or more halogens to impart some degree of flame retardancy without the addition of another flame retardant. When a halogenated flame retardant is present, the flame retardant is desirably present in an amount that can vary depending on the other components present. For example, the halogenated flame retardant can be from about 0.1 weight percent to about 15 weight percent (based on the weight of the core layer), and more specifically from about 1 weight percent to about 13 weight percent based on the weight of the core layer. For example, from about 5 weight percent to about 13 weight percent. If desired, two different halogenated flame retardants may be added to the layer. In other examples, non-halogenated flame retardants can be added, such as flame retardants including, for example, one or more of N, P, As, Sb, Bi, S, Se, and Te. In some embodiments, the non-halogen flame retardant may include a phosphorylated material so that the layer may be more environmentally friendly. When a non-halogen or substantially halogen-free flame retardant is present, the flame retardant is desirably present in an amount that can vary depending on the other components present. For example, the substantially halogen-free flame retardant can range from about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), and more specifically, about 1 weight percent based on the weight of the core layer. It may be present from about 13 weight percent, such as from about 5 weight percent to about 13 weight percent. If desired, two different substantially halogen-free flame retardants may be added to one or more of the core layers described herein. In certain instances, one or more of the core layers described herein may include one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. good. When two different flame retardants are present, the combination of the two flame retardants may be present in varying amounts of flame retardant depending on the other ingredients present. For example, the total weight of the flame retardants present may range from about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), and more specifically from about 1 weight percent to about 1 weight percent based on the weight of the core layer. It may be 15 weight percent, such as about 2 weight percent to about 14 weight percent. The flame retardants used in the layers described herein can be added to the mixture containing the thermoplastic material and fibers (prior to disposing the mixture onto a wire screen or other processing component) or layer can be added after the is formed. In some examples, the flame retardant material may include one or more of an expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

In certain embodiments, skin layers 610, 620 may be the same or different. In one example, skin layer 610 can be a decorative or patterned layer, and skin layer 620 can be a decorative or patterned layer or other type of skin layer. If one or both of the skin layers 610, 620 are patterned layers, the pattern may be the same or different in different regions of the skin layer. In some embodiments, the skin layer has a wood grain pattern (FIG. 10A), a marble pattern (FIG. 10B), a tile pattern (FIG. 10C), a random pattern (FIG. 10D), a whirligig pattern (FIG. 10E), or a herringbone pattern (FIG. 10E). 10F), brick pattern (Fig. 10G), offset staggered brick pattern (Fig. 10H), offset pattern (Fig. 10I), lattice pattern (Fig. 10J), stacked vertical pattern (Fig. 10K), basket weave pattern (Fig. 10L), A pattern can be included that is one or more of a diamond pattern (FIG. 10M), a chevron pattern (FIG. 10N), or a French pattern (FIG. 10O). Other patterns are also possible. In some embodiments, the pattern may already be present on the skin layer material when it is on roll 605 or roll 615. In other examples, a pattern can be printed on the skin layer before applying the skin layer to the core layer. Diagrams of systems that can include printers for printing patterns on skin layers are described in more detail below. If one of the skin layers 610, 620 is a patterned skin layer, the other skin layer may be, for example, a thermoplastic film, a polyolefin film, an elastomer film, or the like. In certain configurations, the film comprises a polyolefin, such as polyethylene or polypropylene, at least one poly(etherimide), at least one poly(etherketone), at least one poly(ether-etherketone), at least one poly(phenylene). sulfide), poly(arylene sulfone), at least one poly(ether sulfone), at least one poly(amideimide), poly(1,4-phenylene), at least one polycarbonate, at least one nylon, and at least one silicone Contains at least one of the following. In other examples, the other skin layer may be, for example, a frim (film + scrim), a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a non-woven fabric, or an inorganic coating, an organic coating, or It may also be present as a thermosetting coating. In other examples, other skin layers may include a critical oxygen index greater than about 22, as measured according to 1996 ISO 4589. If the fibrous scrim is present as (or as part of) another skin layer, the fibrous scrim may include glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and It may include at least one metallized inorganic fiber. Optionally, the scrim can include materials or fibers made from one or more of the thermoplastic materials described above in connection with the core layer. If the thermosetting coating is present as (or as part of) another skin layer, the coating may include at least one of unsaturated polyurethanes, vinyl esters, phenolics, and epoxies. If the inorganic coating is present as (or as part of) another skin layer, the inorganic coating may include a cation-containing mineral selected from Ca, Mg, Ba, Si, Zn, Ti and Al; Alternatively, it may contain at least one of gypsum, calcium carbonate, and mortar. When present as (or as part of) another skin layer, the nonwoven may include thermoplastic materials, thermosetting binders, inorganic fibers, metallic fibers, metallized inorganic fibers, and metalized synthetic fibers. Optionally, other skin layers may also include lofting agents, expandable graphite materials, flame retardant materials, fibers, and the like.

In certain embodiments, the composite articles described herein can have desired surface properties on at least one surface. For example, the core layer of the articles described herein can be roughened due to the presence of reinforcing fibers. Adding a patterned layer to the core layer can reduce the overall surface roughness and/or mask the roughness of the core layer. Surface roughness can be measured in many ways, but the average arithmetic deviation of the profile (Ra), the root mean square of the profile height (Rq), and the maximum height (Rt) are measures of surface roughness. Three roughness parameters can be used. Ra is the average distance from the profile to the mean line over the evaluation length, Rq is the root mean square of the profile height over the evaluation length, and Rt is the highest and lowest point of the profile within the evaluation length. is the vertical distance between the points. For example, L. Mummery (1990) Surface Texture Analysis: A Handbook, Hommelwerke, p. See 106. The results are shown in Table 2 below. Surface roughness can be measured using a stylus profile measuring device and is generally measured according to JIS (JIS-B0601-2001, JIS-B0601-1994, JIS B0601-1982), VDA, ISO 4287:1997, and ANSI Complies with the standards of The parameters (Ra, Rq, Rz and Rt) can be characterized according to ISO 4287:1997.

In certain embodiments, the surface roughness (Ra) of at least one surface of the composite article, e.g., the surface comprising the patterned layer, is measured by a stylus profilometer according to ISO 4287:1997 in the longitudinal and transverse directions. may be less than 10, 8, 8, 7, 6, 5, 4 or 3 microns in diameter. In other embodiments, the surface roughness (Ra) of the surface comprising the patterned layer of the thermoplastic composite article is 2 microns in the machine and transverse directions, as measured by a stylus profilometer according to ISO 4287:1997. less than In another example, the average RMS profile height (Rq) of at least one surface of the composite article, e.g., a surface comprising a patterned layer, is measured by a stylus profilometer according to ISO 4287:1997 in longitudinal and lateral directions. It can be less than 12, 11, 10, 9, 8, 7, 6, or 5 microns in the direction. In other embodiments, the average RMS profile height (Rq) of the surface of the thermoplastic composite article that includes the patterned layer is determined in the machine and transverse directions as measured by a stylus profilometer according to ISO 4287:1997. Less than 4 microns. In other examples, the maximum height (Rt) of at least one surface of the composite article, e.g., the surface comprising the patterned layer, is determined in the longitudinal and transverse directions as measured by a stylus profilometer according to ISO 4287:1997. It can be less than 80, 70, 60, 50, 40, 35 or 30 microns. In other embodiments, the maximum height (Rt) of the surface comprising the patterned layer of the thermoplastic composite article is less than 30 microns in the machine and transverse directions, as measured by a stylus profilometer according to ISO 4287:1997. It is.

In certain configurations, the system can be used to perform inline processes. A diagram of the components of the system is shown in FIG. 11A. System 1100 includes reservoirs 1102, 1104. Reservoir 1102 can receive thermoplastic material and reservoir 1104 can receive reinforcing fibers. Reservoirs 1102, 1104 can supply materials to a mixing tank 1106. A mixing tank 1106 can be fluidly coupled to a spray head or nozzle 1108 for spraying the mixed dispersion onto a moving support 1110. The web 1115 on the moving support 1110 can be moved through a vacuum or other pressure device 1120 that can remove liquid from the web 1115 to form a core layer 1122. Core layer 1122 may pass through dryer 1125 to dry and heat the core layer. Skin layers 1130, 1140 can be applied on opposite surfaces of core layer 1122 from a feeding device or roll 1135, 1145, respectively, to provide a composite article. The composite article may be passed through a set of rollers 1160, 1162 to consolidate the composite article. The consolidated composite article may be cut into individual articles by cutting device 1170 as the moving sheet of consolidated thermoplastic composite article passes through cutting device 1170. For example, a processor 1180 is shown that can control movement of moving support 1110, spraying of material onto moving support 1110, and other equipment and parameters used by system 1100.

In certain examples, system 1100 can include other components that can be present before or after cutting device 1170. For example, the system 1100 may include another cutting station 1175 (FIG. 11B) designed to cut a tongue into one edge of a composite article and a groove into an opposite edge of the composite article. can be included. This engraving allows different individual panels to fit into each other in use, so there is some panel overlap at the joint. In other examples, the system 1100 can include another heating device 1185 (FIG. 11C) that can be used to loft or increase the thickness of the composite article. Heating device 1185 can be placed before or after cutting device 1170 as desired. An optional adhesive reservoir 1190 (FIG. 11D) may be present to provide adhesive to the core layer before applying the skin layer 1130. A second adhesive reservoir (not shown) may also be present to provide adhesive to the core layer before applying the skin layer 1140.

In some embodiments, system 1200 can include multiple sets of different rollers, including rollers 1160, 1162 and rollers 1212, 1214, as shown in FIG. Different rollers may be present at different temperatures or may provide different gap thicknesses to compress the composite article before it exits the moving support. In some examples, the rollers 1212, 1214 can be used to compress the edges of the composite article to a higher degree such that the overall thickness at the edges of the composite article lower than the central area of the article. The thickness at different edges may be the same or different.

In other embodiments, the system can include a printer 1310 that can print a pattern on the skin layer before applying the skin layer to the core layer, as shown in FIG. 13. The printer 1305 sprays or prints inks and other materials, such as fibers, particles, powders, etc., onto the surface of the skin layer before the skin layer is applied to the core layer or after the skin layer is applied to the core layer. , or can be deposited. A printer 1305 can be positioned near the roll 1335 to print a pattern on the surface of the skin layer 1330 as it is unrolled from the roll 1335 of the skin layer. Although not shown, the printer may be positioned to apply the patterned layer to the skin layer 1340 after the patterned layer is applied to the surface of the core layer 1122. The exact pattern provided by the printer can vary and may be different in different areas of the skin layer. For example, patterns printed on the skin layer include wood grain pattern, marble pattern, tile pattern, random pattern, whirligig pattern, herringbone pattern, brick pattern, offset staggered brick pattern, offset pattern, lattice pattern, stacked vertical pattern, French The pattern may be one or more of a pattern, a basket weave pattern, a diamond pattern, or a chevron pattern.

In certain embodiments, sidewalls can be manufactured using the in-line processes and systems described herein. Sidewalls can be present on recreational or other vehicles, cubicles, office walls, residential walls, or other environments. The RV wall 1400 includes a porous core layer 1412, a first skin layer 1414 on a first surface of the porous core layer 1412, and a patterned second skin layer 1414 on a second surface of the porous core layer. An example is shown in FIG. 14 that includes a first laminated lightweight reinforced thermoplastic composite article 1410 that includes a skin layer 1416. Patterned skin layer 1416 is typically placed facing the interior of the space defined by RV wall 1400. The RV wall 1400 can also include a foam layer 1420 bonded to a first laminated lightweight reinforced thermoplastic composite article 1410 at a first surface of the foam layer. For example, the foam layer 1420 is the first skin layer 1414 of the first laminated lightweight reinforced thermoplastic composite article 1410 such that the patterned second skin layer 1416 is on the inner surface of the RV wall 1400. can be coupled to the first laminated lightweight reinforced thermoplastic composite article 1410 via. RV wall 1400 also typically includes a support structure 1430, which can take the form of a chassis, tube, cage, or other structure. Support structure 1430 typically includes a metal or metals, such as steel, aluminum, and the like. Support structure 1430 may be bonded to a second surface of foam layer 1420 at a first surface of support structure 1430. A second laminated lightweight reinforced thermoplastic composite article 1440 may be coupled to the second surface of support structure 1430. The second laminated lightweight reinforced thermoplastic composite article 1440 includes a porous core layer 1442 , a first skin layer 1444 on a first surface of the porous core layer 1442 , and a second skin layer 1444 on a first surface of the porous core layer 1442 . a second skin layer 1446 on the surface. An exterior panel 1450 can be bonded to a second laminated lightweight reinforced thermoplastic composite article 1440 to form an RV wall 1400. In some examples, exterior panel 1450 includes fiberglass or aluminum.

As described herein, the patterned second skin layer 1416 may include a wood grain pattern, a marble pattern, a tile pattern, a random pattern, a whirligig pattern, a herringbone pattern, a brick pattern, an offset staggered brick pattern, an offset pattern, The pattern may include one or more of a lattice pattern, a stacked vertical pattern, a French pattern, a basket weave pattern, a diamond pattern, or a chevron pattern. In certain embodiments, the first skin layer 1414 of the first laminated lightweight reinforced thermoplastic composite article 1410 comprises a scrim. In a particular example, the porous core layer 1412 of the first laminated lightweight reinforced thermoplastic composite article 1410 comprises a web comprising an open cell structure formed from reinforcing fibers held together by a thermoplastic material as described above. can include. In some examples, the porous core layer 1442 of the second laminated lightweight reinforced thermoplastic composite article includes a web that includes an open cell structure formed from reinforcing fibers held together by a thermoplastic material. In some configurations, the thermoplastic material of each porous core layer 1410, 1440 independently comprises a thermoplastic material described herein, e.g., a polyolefin such as polypropylene, polyethylene, etc. In some embodiments, the reinforcing material of each porous core layer includes reinforcing fibers described herein, such as glass fibers.

In certain embodiments, an RV wall can be present within a recreational vehicle that includes a roof, a sidewall coupled to the roof, and a floor coupled to the sidewall to provide interior space within the recreational vehicle, one example being is shown in FIG. 15, where an RV 1500 includes an RV wall 1510, which may be similar to RV wall 1400 described above. RV 1500 also includes a roof 1512, another sidewall 1514, and a floor 1516. The RV 1500 may include wheels 1552, 1554 to enable traction of the RV, and/or may include an engine, electric motor, or other power source to enable independent movement of the RV. can.

In certain examples, the inline methods and systems described herein may be controlled using one or more processors that may be part of the inline system or otherwise may be electrically coupled to the in-line system via a device such as a computer, laptop, mobile device, etc. For example, the processor can be used to control the mixing speed of the materials, the speed of the moving supports, the pressure used to remove liquid from the dispersion placed, the temperature of the heating device, the pressure applied to the materials, and the process and Other parameters of the system can be controlled. Such a process may be performed automatically by the processor without requiring user intervention, or the user may input parameters via a user interface. In certain configurations, the processor may include one or more microprocessors and/or appropriate software for operating the system, e.g., to control various fluid reservoirs, mixing tanks, pressure devices, temperatures, etc. computer systems and/or common hardware circuitry. The processor may be integral to the in-line system or may reside on one or more accessory boards, printed circuit boards, or computers electrically coupled to components of the in-line system. The processor typically is electrically connected to one or more memory units to receive data from other components of the system and to enable adjustment of various system parameters as necessary or desired. be combined. Processors include Unix (registered trademark), Intel PENTIUM (registered trademark) type processor, Intel Core (trademark) processor, Intel Xeon (trademark) processor, AMD Ryzen (trademark) processor, AMD Athlon (trademark) processor, AMD FX (trademark) ) processor, an Apple-designed processor, including the Motorola PowerPC, Sun UltraSPARC, Hewlett-Packard PA-RISC processor, Apple A14 Bionic processor, A13 Bionic processor, A12 processor, Apple A11 processor, or any other to the type of processor It may be part of a general-purpose computer, such as one based on One or more of any type of computer system may be used in accordance with various embodiments of the present technology. Additionally, the system may be connected to a single computer or distributed among multiple computers connected by a communications network. If desired, different components of the inline system may be controlled by respective processors or computers that are separate from the processors or computers used to control other components of the inline system. It should be understood that other functions may be performed, including network communications, and the technology is not limited to having any particular function or set of functions. Various aspects may be implemented as special purpose software running on a general purpose computer system. A computer system may include a processor coupled to one or more memory devices, such as a disk drive, memory, or other device for storing data. Memory is typically used to store programs, temperatures, moving support speeds, and other values used in in-line processes. The components of a computer system may include one or more buses (e.g., between components integrated within the same machine) and/or networks (e.g., between components residing on separate individual machines). can be combined by an interconnection device that can. Interconnect devices provide communications (eg, signals, data, instructions) exchanged between components of a system. Computer systems are typically capable of receiving and/or issuing commands within a processing time of, for example, a few milliseconds, a few microseconds, or less to enable rapid control of the system. The processor is typically electrically coupled to a power source, which can be, for example, a direct current source, an alternating current source, a battery, a solar cell, a fuel cell, or other power source, or a combination of power sources. The power supply may be shared by other components of the system. The system also includes one or more input devices, e.g., a keyboard, mouse, trackball, microphone, touch screen, manual switches (e.g., override switches), and one or more output devices, e.g., a printing device, a display. Can include screen and speakers. Additionally, the system may include one or more communications interfaces (in addition to or in place of the interconnect device) that connect the computer system to a communications network. The system may also include appropriate circuitry for converting signals received from various electrical devices present within the system. Such circuitry may be present on a printed circuit board or connected to a suitable interface, such as a Serial ATA interface, an ISA interface, a PCI interface, a USB interface, a Fiber Channel interface, a Firewire interface, an M. 2 connector interface, PCIE interface, mSATA interface, etc. or via one or more wireless interfaces, such as Bluetooth, Wi-Fi, near field communication or other wireless protocols and/or interfaces. may be present on a separate substrate or device electrically coupled to.

In certain embodiments, a storage system used in the systems described herein typically includes a computer readable and writable non-volatile storage medium, which includes a computer readable and writable non-volatile storage medium that is used by a program executed by a processor. Software code that may be executed or information processed by a program may be stored on or in the medium. The medium may be, for example, a hard disk, solid state drive, or flash memory. Programs or instructions executed by a processor may be located locally or remotely and may be obtained by the processor through an interconnection mechanism, communication network, or other means as desired. Typically, during operation, a processor reads data from a non-volatile storage medium into another memory that allows faster access to the information by the processor than the medium. This memory is typically volatile random access memory, such as dynamic random access memory (DRAM) or static memory (SRAM). This may be located within a storage or memory system. Processors typically manipulate data in integrated circuit memory and then copy the data to a medium after processing is complete. Various mechanisms are known for managing data movement between media and integrated circuit memory elements, and the present technology is not limited thereto. The technology is also not limited to any particular memory or storage system. In certain embodiments, the system also includes specially programmed dedicated hardware, such as an application specific integrated circuit (ASIC), a microprocessor unit (MPU), or a field programmable gate array (FPGA), or a combination thereof. can be included. Aspects of the present technology may be implemented in software, hardware or firmware, or any combination thereof. Furthermore, such methods, acts, systems, system elements, and components thereof may be implemented as part of the systems described above or as independent components. Although a particular system is described by way of example as one type of system on which various aspects of the present technology may be implemented, it is understood that the aspects are not limited to being implemented on the systems described. sea bream. Various aspects may be implemented on one or more systems having different architectures or components. The system can include a general purpose computer system programmable using a high level computer programming language. The system may also be implemented using specially programmed dedicated hardware. In the system, the processor is typically a commercially available processor, such as the well-known microprocessors available from Intel, AMD, Apple, and the like. Many other processors are also commercially available. Such processors typically run, for example, the Windows 7, Windows 8 or Windows 10 operating systems available from Microsoft, MA such as Snow Leopard, Lion, Mountain Lion, Mojave, High Sierra, El Capitan, etc. C OS (registered trademark) , or other versions available from Apple, the Solaris operating system available from Sun Microsystems, or the UNIX or Linux operating systems available from various sources. Many other operating systems may be used, and in certain embodiments, a simple set of commands or instructions may function as an operating system.

In a particular example, a processor and an operating system may together define a platform on which high-level programming language application programs can be written. It should be understood that the technology is not limited to any particular system platform, processor, operating system, or network. Additionally, it will be apparent to those skilled in the art, given the benefit of this disclosure, that the present technology is not limited to any particular programming language or computer system. Additionally, it should be understood that other suitable programming languages and other suitable systems may also be used. In particular examples, the hardware or software may be configured to implement a cognitive architecture, neural network, or other suitable implementation. If desired, one or more portions of the computer system may be distributed across one or more computer systems coupled to a communications network. These computer systems may also be general purpose computer systems. For example, various aspects may include one or more computers configured to provide a service (e.g., a server) to one or more client computers or to perform an entire task as part of a distributed system. May be distributed between systems. For example, various aspects may be performed on a client-server or multi-tier system that includes components distributed across one or more server systems that perform various functions in accordance with various embodiments. These components may be executable code, intermediate code (e.g., IL), or interpreted code (e.g., Java) may be used. It should also be understood that the present technology is not limited to running on any particular system or group of systems. Also, it should be understood that the technology is not limited to any particular distributed architecture, network, or communication protocol.

In some cases, using an object-oriented programming language such as, for example, SQL, SmallTalk, Basic, Java, JavaScript, PHP, C++, Ada, Python, iOS/Swift, Ruby on Rails or C# (C-Sharp), Various embodiments can be programmed. Other object oriented programming languages may also be used. Alternatively, functions, scripts, and/or logic programming languages may be used. Various constructs can be written in HTML, XML, or other formats that, when displayed in a non-programmed environment (e.g., a browser program window, render aspects of a graphical user interface (GUI) or perform other functions). (a document created in a format). Certain configurations may be implemented as programmed or unprogrammed elements, or any combination thereof. In some examples, the system includes a mobile device, tablet, laptop computer, or other portable device that can communicate via wired or wireless interfaces and allows remote operation of the system in-line if desired. A remote interface, such as the one that exists above, can be provided.

In certain examples, the processor may also include or have access to a database of information regarding the particular article being manufactured. For example, specific parameters used to manufacture a core layer of desired thickness and composition can be obtained from a database and used by an in-line system. The instructions stored in memory may execute software modules or control routines for the system, and may in fact provide a controllable model of the system in-line. The processor uses information accessed from the database in conjunction with one or more software modules running within the processor to determine control parameters or values for different components of the system, e.g., different temperatures, different pressures, different compaction devices. etc. can be determined. Using input interfaces for receiving control instructions and output interfaces linked to different system components within the system, the processor can exercise active control over the system.

Specific examples of LWRT articles manufactured and tested using in-line processes are described below.

Example 1

LWRT articles were prepared by adding chopped glass fibers (e.g., 30-70 wt%) to a polypropylene (PP) resin matrix as reinforcement to form a web or core in an in-line process as described herein. . A first skin (a non-woven scrim with a basis weight of 23 gsm or g/m ² ) is added to one surface of the core and a second skin (105 g/m ² with a marble or wood grain pattern) is added with in-line calendering. The skin was pressed onto the core in addition to the opposite surface using an in-line process to form the LWRT article.

Example 2

Various physical and analytical tests were performed on 99 mm diameter disks cut from the LWRT article of Example 1. Areal density (g/ ^m2 or gsm, 5 series), ash content (%, 5 series), density (g/ ^cm3 , 5 series) and as-manufactured thickness (mm, 5 series) of laminated decorative panels was measured. The results are shown in Table 1 below.
Table 1 Physical properties of inline laminated LWRT composite decorative panels.

Since the PP/glass LWRT composite substrate has a porous structure with high void content, a significantly lower density was achieved. The density is 0.35 and 0.36 g/ ^cm3 for the two samples respectively. These LWRT composites are approximately 50% lighter than regular plywood and comparable to modified plywood. The areal density and ash content of the two completed LWRT/Decor samples were very close with standard deviation values ranging ±5% of the mean value, indicating that these inline laminated decorative composite panels were very uniform. There is. The thickness of these in-line laminated decorative panels meets the 2.9±0.2 mm flatness requirement for these decorative panels used for the interior layers of RV sidewalls. Photographs of the wood grain (Figure 16A) and marble pattern (Figure 16B) are shown.

Example 3

LWRT specimens from the LWRT article of Example 1 having a size of 75 mm x 75 mm were cut from LWRT boards without surface skin and from LWRT boards laminated with decor (wood grain and marble) by an in-line lamination process. The surface roughness of 10 samples was measured. One measurement was taken on each surface roughness specimen along the machine direction (MD) and cross-machine direction (CD) using a stylus profile measurement device (Mitutoyo Surftest SJ-210). The tracing speed, stylus tip diameter, and tip angle were 10 mm/min, 4 mm, and 90 degrees, respectively. Three roughness parameters were recorded: the average arithmetic deviation of the profile (Ra), the root mean square of the profile height (Rq), and the maximum height (Rt). Ra is the average distance from the profile to the mean line over the evaluation length, Rq is the root mean square of the profile height over the evaluation length, and Rt is the highest and lowest point of the profile within the evaluation length. is the vertical distance between the points. For example, L. Mummery (1990) Surface Texture Analysis: A Handbook, Hommelwerke, p. See 106. The results are shown in Table 2 below.
Table 2 Surface roughness parameters of inline laminated decorative panels.

The exposed surface of the PP/glass LWRT composite has Ra, Rq and It has an Rt value. The surface roughness is higher in the CD than in the MD, indicating better alignment of the glass fibers in the longitudinal direction than in the transverse direction during the in-line lamination process. In both MD and CD, the Ra, Rq and Rt values of both decorative patterns are significantly lower than those of the PP/glass LWRT exposed surface, which further suggests that these types of decors can be laminated onto LWRT composite substrates. It is shown that the porous structure of the LWRT core board can be covered and the surface smoothness and appearance can be effectively improved accordingly. For example, the Ra is significantly reduced from the exposed surface of PP/glass LWRT to the surface of the wood grain pattern decor panel to 1.4 microns in both MD and CD, which is lower than the surface roughness (Ra) of plywood. . These results are consistent with the decorative layer, especially the wood grain pattern, and is thick enough to sufficiently cover the core texture of the LWRT composite.

Example 4

デコールもスクリムも複合コア基板から分離することができず、周囲条件下でスキン材料とＰＰ／ガラスＬＷＲＴコア基板との間の良好な界面結合を示した。 Two laminated decorative samples with a Woodgrain or Marble pattern were subjected to a 180 degree peel test on a decor side and a scrim side in an MTS testing machine with a 250N load cell according to ASTM Standard D 903-2004. went. Rectangular (25 mm x 100 mm) test pieces (10 series) were cut out from the manufactured sheet in the MD and CD directions. The crosshead speed, span, anvil diameter, and nose diameter were 15 mm/min, 64 mm, 6.4 mm, and 6.4 mm, respectively. The results are shown in Table 3.
Table 3 Adhesion strength between decor or scrim and LWRT composite core substrate.

Neither the decor nor the scrim could separate from the composite core substrate, indicating good interfacial bonding between the skin material and the PP/glass LWRT core substrate under ambient conditions.

Example 5

Flat tensile (FWT) testing of as-manufactured decorative panels of two samples (Woodgrain and Marble) was conducted on an MTS mechanical testing machine according to ASTM C297-04. Ten test pieces (51 mm x 51 mm) were cut out from the manufactured panel in the CD direction. The crosshead speed was 50 mm/min and the load cell was 5 kN. Place each specimen onto a tensile jig/end tab (top and bottom) with urethane glue/adhesive (3M Scotch-Weld 3535, weight ratio of base to accelerator 100:105, density approximately 1.29 g/cm ³ ), and the adhered sample was left in the air for 24 hours to completely cure the adhesive. Flat tensile (FWT) strength is a desirable criterion for flat panels used in RV sidewall applications. The results are shown in FIG. 17A (wood grain skin) and FIG. 17B (marble skin).

From the photographs of the tested specimens, it can be seen that almost all specimens failed on the surface of the decor or due to failure of the adhesive at the interface between the decor and the test fixture. The average peak load values for the Woodgrain and Marble samples were 1545 and 1172 N, respectively, which are significantly higher than the majority of FWT peak load values (less than 700 N) for EPS foams reported in the literature; It is one of the most commonly used insulation foams in RV sidewall construction. These results are consistent with the as-manufactured decorative panel being much stronger in the z-direction compared to EPS foam, reducing the likelihood that the finished RV sidewall panel will not delaminate within the decorative panel. .

Example 6

Bending (3-point bending) testing was performed on as-manufactured laminate panels (Woodgrain and Marble) according to ASTM D790-2007. Rectangular (25 mm x 100 mm) specimens (10 series) in both MD and CD directions were cut from the panels. Testing was conducted using an MTS mechanical testing machine using a 250N load cell with the scrim or decor side of the sample facing the load. The crosshead speed, span, anvil diameter, and nose diameter were 15 mm/min, 64 mm, 6.4 mm, and 6.4 mm, respectively. The significance of flexural strength and modulus was determined using the Tukey test at an α level of 0.05 using the software R version Ri386-3.5.0 (The R Foundation, https://www.r-project.org/ ) was statistically analyzed using one-way analysis of variance (ANOVA). The results are shown in FIG. 18A (peak load) and FIG. 18B (elastic modulus).

For bending strength (peak load) with the scrim face facing the load (or facing up) during the bending test, the wood grain sample has significantly higher strength (20% higher) than the MD marble sample. With the decor or scrim side facing up, the stiffness of the wood grain samples has significantly higher values than the MD marble samples. For example, the slope values for the wood grain sample are 26% and 40% higher than the marble sample when the scrim and decor sides are facing upwards, respectively, during testing. The overall trend for both samples is that the flexural strength and stiffness are better in MD than in CD, again due to better glass orientation in MD than in CD. Furthermore, in both the MD and CD of both samples, the up-turned decor side can have higher strength and stiffness than the up-up scrim side during testing. This means that by laminating a decor skin layer onto the LWRT composite, the overall strength and stiffness of the resulting decorative panel is improved compared to LWRT that is double-sided as a scrim, such as is used in RV sidewall construction. It suggests that it will be done.

Example 7

ＦＭＶＳＳ ３０２試験から、ＷｏｏｄｇｒａｉｎサンプルはＭａｒｂｌｅサンプルよりも３０％遅く燃焼した。Ｗｏｏｄｇｒａｉｎサンプルの火炎伝播指数（ＦＳＩ）は２５であり、クラスＡ性能（ＦＳＩ≦２５）を満たし、煙発生指数（ＳＤＩ）は５０であり、クラスＡ、ＢまたはＣの要件（ＳＤＩ≦４５０）よりも大幅に低かった。対照的に、Ｍａｒｂｌｅサンプルは、１２５のＦＳＩおよび３０のＳＤＩを有し、クラスＣ要件を満たす。これら２つのサンプル間の唯一の違いは、化粧材料の化粧パターンであった。したがって、Ｗｏｏｄｇｒａｉｎサンプルのより良好なＦＲ性能は、大理石様パターンおよび木目パターンとの違いに起因する可能性がある。しかしながら、Ｍａｒｂｌｅサンプルは、ＡＳＴＭ Ｅ８４クラスＣのＲＶ側壁の単一成分に対するＦＲ要件を既に満たしている。 Flammability performance was evaluated according to two standards: Federal Motor Vehicle Safety Standard (FMVSS 302-03) and ASTM E84. Although FMVSS 302 is more commonly accepted in automotive interior applications, performance tested by the ASTM E84 method provides more insight into the performance expected by the building and construction industry, including the RV industry. Specimens were cut to 304.8 mm x 25.4 mm and tested horizontally according to FMVSS 302. For ASTM E84 testing, both samples (Woodgrain and Marble) were cut to 0.61 m x 1.83 m and tested for Flame Spread Index (FSI) and Smoke Development Index (SDI) to classify the material as Class A, B or C. ) was evaluated. The results are shown in Table 4.
Table 4 Combustion performance of two decorative panels.

From the FMVSS 302 test, the Woodgrain sample burned 30% slower than the Marble sample. The Woodgrain sample has a Flame Spread Index (FSI) of 25, meeting Class A performance (FSI ≤ 25), and a Smoke Development Index (SDI) of 50, meeting the requirements of Class A, B or C (SDI ≤ 450). was also significantly lower. In contrast, the Marble sample has an FSI of 125 and an SDI of 30, meeting Class C requirements. The only difference between these two samples was the cosmetic pattern of the cosmetic material. Therefore, the better FR performance of the Woodgrain sample may be due to its difference from marble-like and woodgrain patterns. However, the Marble sample already meets ASTM E84 Class C FR requirements for single component RV sidewalls.

Example 8

The sound absorption properties and sound absorption coefficients of the article of Example 1 and the Luan/NPP decorative panel were determined using the two-microphone transfer function method according to the ASTM E1050-98 standard. Luan plywood panels were laminated using NPP patterned decorative paper through a secondary lamination process. The frequency range in which the evaluation was performed was 100 to 6500 Hz. All samples were tested with the decorative or scrim side (exposed luan side of the luen/NPP panel) facing the sound source. The results are shown in FIG. 19A (decorative surface facing the sound source) and FIG. 19B (scrim surface facing the sound source).

Different test samples with the following compositions: ST-13792 contained an LWRT core layer with a basis weight of 1200 g/ ^m2 , a thickness of 3.6 mm, 45 wt% polypropylene and 55 wt% glass fibers. . ST-13793 included an LWRT core layer with a basis weight of 1670 g/m ² , a thickness of 4.7 mm, 50% polypropylene and 50% glass fiber by weight. All other test samples had an LWRT core layer with a basis weight of 960 g/ ^m2 , a thickness of 2.7 mm, 45 wt% polypropylene and 55 wt% glass fibers. The overall dimensions of each sheet sample produced were approximately 1219 mm wide by 2438 mm long (approximately 4 feet by 8 feet). Sample ST-13378 included a marble patterned layer on the exterior surface. Samples ST-13794 and ST-13882 included a fabric patterned layer on the exterior surface. The remaining samples include a wood grain patterned layer on the outer surface.

Acoustic characterization of the materials was based on the sound absorption coefficient α. This parameter is the ratio of the absorbed sound intensity to the incident sound intensity on the surface. If the α value is close to 1 and there is an absorption plateau at this value over a wide frequency range, the material can be considered to have good sound absorption properties. The sound absorption capacity of LWRT articles can be influenced by various factors such as areal density, density, thickness, and filler (type and content).

Over the entire frequency range (100-6500 Hz), the sound absorption coefficient of the test samples was significantly higher than the Luan/NPP decorative panel, no matter which surface faced the sound source. When the decorative paper side was facing the sound source, the coefficient varied from 0.1 to 0.5, while this value was about 0.1-0.2 for the Luan/NPP panel. When the scrim surface faced the sound source, the coefficient values varied from 0.1 to 0.9 for RVX 3.6 core (ST-13792) and RVZ 4.7 core (ST-13793) based samples. . The RVX 2.7 core-based samples showed this coefficient ranging from 0.1 to 0.7, while the Luan/NPP samples only had this value between 0.1 and 0.2. LWRT panels can significantly reduce sound/noise reflections compared to Luan/NPP panels. The thicker the substrate, the better the sound absorption performance.

When introducing elements of examples disclosed herein, the articles "a," "an," "the," and "said" are intended to mean that there is one or more of the elements. ing. The terms "comprising," "including," and "having" are intended to be open-ended, meaning that additional elements beyond those listed may be present. means. It will be appreciated by those skilled in the art, given the benefit of this disclosure, that various components of the embodiments can be replaced or replaced with various components of other embodiments.

Although particular aspects, configurations, examples, and embodiments have been described above, additions, substitutions, modifications, and changes to the disclosed exemplary aspects, configurations, examples, and embodiments may be made in light of the benefit of this disclosure. It will be recognized by those skilled in the art that this is possible.

Claims (42)

An in-line process for manufacturing thermoplastic composite articles using an in-line system, the process comprising:
mixing the reinforcing material and the thermoplastic material in an aqueous solution;
placing the aqueous solution containing the reinforcing material and the thermoplastic material on a moving support;
removing water from the disposed aqueous solution on the moving support to form a web comprising an open cell structure formed from the reinforcing material and the thermoplastic material;
drying the web on the moving support to provide a porous core layer;
heating the dry porous core layer on the moving support to melt the thermoplastic material of the heated porous core layer;
disposing a first skin layer on a first surface of the heated porous core layer on the moving support;
disposing a second skin layer on a second surface of the heated porous core layer on the moving support;
applying pressure to the heated porous core layer including the disposed first skin layer and the disposed second skin layer on the moving support to provide a thermoplastic composite article; Inline processes, including and. 2. The in-line process of claim 1, wherein the porous core layer is heated at a first temperature above the melting point of the thermoplastic material and below the melting point of the reinforcing material. 2. The in-line process of claim 1, further comprising adding foam to the aqueous solution of the reinforcing material and the thermoplastic material. The in-line process of claim 1, further comprising adding a lofting agent to the aqueous solution of the reinforcing material and the thermoplastic material. The in-line process of claim 1, further comprising configuring the first skin layer as a scrim. 6. The in-line process of claim 5, further comprising configuring the second skin layer as a patterned layer. The patterns of said patterned layers include wood grain pattern, marble pattern, tile pattern, random pattern, whirligig pattern, herringbone pattern, brick pattern, offset staggered brick pattern, offset pattern, lattice pattern, stacked vertical pattern, French pattern, basket weave. 7. The in-line process of claim 6, wherein the in-line process is one or more of a pattern, a diamond pattern, or a chevron pattern. 8. The in-line process of claim 7, wherein the thermoplastic material comprises polyolefin and the reinforcing material comprises inorganic fibers. The in-line process of claim 1, wherein the surface roughness (R _a ) of the thermoplastic composite article is less than 3 microns in the machine and transverse directions, as measured by a stylus profilometer according to ISO 4287:1997. . The in-line process of claim 1, wherein the surface roughness (R _a ) of the thermoplastic composite article is less than 2 microns in the machine and transverse directions, as measured by a stylus profilometer according to ISO 4287:1997. . The first skin layer is disposed on the heated porous core layer without the use of an adhesive between the first skin layer and the heated porous core layer. Inline process according to item 1. 2. The method of claim 1, further comprising disposing an adhesive on the second surface of the heated porous core layer prior to disposing the second skin layer on the second surface. inline process. 15. The in-line process of claim 14, wherein the adhesive comprises a polyolefin or polyurethane. The in-line process of claim 1, further comprising cutting a groove in the first end of the thermoplastic composite panel. 15. The in-line process of claim 14, further comprising cutting a tongue in the second end of the thermoplastic composite panel. consolidating the heated porous core layer before disposing the first skin layer on the first surface and before disposing the second skin layer on the second surface; The in-line process of claim 1, further comprising: The in-line process of claim 1, further comprising heating the thermoplastic composite article after compacting the thermoplastic composite article to increase the overall thickness of the thermoplastic composite article. . 2. The method of claim 1, further comprising printing a pattern on the second skin layer before disposing the second skin layer on the second surface of the heated porous core layer. inline process. 2. The method of claim 1, further comprising printing a pattern on the second skin layer after disposing the second skin layer on the second surface of the heated porous core layer. Inline process. further comprising compressing side edges of the heated porous core layer, the compressed side edges of the heated porous core layer having a thickness less than a central region of the heated porous core layer. The in-line process of claim 1, wherein the in-line process also has a small thickness. An in-line system configured to manufacture a thermoplastic composite article, the system comprising:
a fluid reservoir configured to receive an aqueous solution, a thermoplastic material, and a reinforcing material, the fluid reservoir configured to receive an aqueous solution, a thermoplastic material, and a reinforcing material; a fluid reservoir configured to provide a uniform dispersion of the material;
a moving support fluidly coupled to the fluid reservoir and configured to receive the uniform dispersion from the fluid reservoir and retain the uniform dispersion on the moving support; and,
a pressure device configured to remove water from the uniform dispersion on the moving support to provide a web comprising an open cell structure formed from the reinforcing material and the thermoplastic material;
an apparatus configured to dry and heat the web on the moving support to provide a porous core layer on the moving support;
a first supply device configured to receive a first skin material, the first skin material as a first skin layer on a first surface of the porous core layer on the moving support; a first dispensing device configured to provide above;
a second supply device configured to receive a second skin material, the second skin material as a second skin layer on a second surface of the porous core layer on the moving support; a second supply device configured to provide a second supply device;
The heated porous core layer is removed from the heated porous core layer by applying pressure to the heated porous core layer, the disposed first skin layer, and the disposed second skin layer. and a compaction device configured to compact the skin layer and the disposed second skin layer to provide a substantially flat thermoplastic composite article. 22. The in-line system of claim 21, wherein the first supply device is configured to receive a roll of the first skin material. 23. The in-line system of claim 22, wherein the second supply device is configured to receive a roll of the second skin material. 22. The in-line system of claim 21, wherein the in-line system further comprises an apparatus configured to cut the thermoplastic composite article into individual sheets as the thermoplastic composite article exits the moving support. system. further comprising a second heating device disposed after the consolidation device, the second heating device heating the thermoplastic composite article to increase the overall thickness of the thermoplastic composite after consolidation. 22. The in-line system of claim 21, wherein the in-line system is configured to increase speed. 22. The in-line system of claim 21, further comprising a sprayer fluidly coupled to the fluid reservoir, the sprayer configured to spray the uniform dispersion onto the moving support. disposing an adhesive on the second surface of the heated porous core layer before disposing the second skin layer on the second surface of the heated porous core layer; 22. The in-line system of claim 21, further comprising an adhesive reservoir configured to. Claim further comprising: a printer configured to print a pattern on the second skin layer after the second skin layer is disposed on the second surface of the heated porous core layer. In-line system according to item 21. further comprising a printer configured to print a pattern on the second skin material before the second skin layer is disposed on the second surface of the heated porous core layer; An in-line system according to claim 21. 22. The in-line system of claim 21, further comprising a processor configured to control movement of the moving support. A wall for a recreational vehicle,
a porous core layer, a first skin layer on a first surface of the porous core layer, and a patterned second skin layer on a second surface of the porous core layer. a first laminated lightweight reinforced thermoplastic composite article;
a foam layer bonded to the first laminated lightweight reinforced thermoplastic composite article at a first surface of the foam layer; A foamed foam bonded to the first laminated lightweight reinforced thermoplastic composite article via a skin layer, such that the patterned second skin layer is present on the inner surface of the wall of the recreational vehicle. body layer and
a support structure, a first surface of the support structure coupled to a second surface of the foam layer;
a second laminated lightweight reinforced thermoplastic composite article bonded to a second surface of the support structure, the article comprising a porous core layer and a first skin layer on a first surface of the porous core layer; and a second skin layer on a second surface of the porous core layer.
an exterior panel bonded to the second laminated lightweight reinforced thermoplastic composite article. 32. The recreational vehicle wall panel of claim 31, wherein the exterior panel comprises fiberglass or aluminum. 32. The recreational vehicle wall panel of claim 31, wherein the support structure comprises tubes or a network. The patterned second skin layer may include a wood grain pattern, a marble pattern, a tile pattern, a random pattern, a whirligig pattern, a herringbone pattern, a brick pattern, an offset staggered brick pattern, an offset pattern, a lattice pattern, a stacked vertical pattern, a French 32. The recreational vehicle wall panel of claim 31, comprising one or more of a pattern, a basket weave pattern, a diamond pattern, or a chevron pattern. 35. The recreational vehicle wall panel of claim 34, wherein the first skin layer of the first laminated lightweight reinforced thermoplastic composite article comprises a scrim. 32. The porous core layer of the first laminated lightweight reinforced thermoplastic composite article comprises a web comprising an open cell structure formed from reinforcing fibers held together by the thermoplastic material. recreational vehicle wall panel. 37. The porous core layer of the second laminated lightweight reinforced thermoplastic composite article comprises a web comprising an open cell structure formed from reinforcing fibers held together by the thermoplastic material. recreational vehicle wall panel. 38. The recreational vehicle wall panel of claim 37, wherein the thermoplastic material in each porous core layer independently comprises a polyolefin. 39. The recreational vehicle wall panel of claim 38, wherein the reinforcing material of each porous core layer comprises fiberglass. 40. The recreational vehicle wall panel of claim 39, wherein the thermoplastic material in each porous core layer is polypropylene. A recreational vehicle comprising a roof, a sidewall coupled to the roof, and a floor coupled to the sidewall for providing an interior space within the recreational vehicle, at least one of the sidewalls comprising: A recreational vehicle comprising a recreational vehicle wall panel according to any one of claims 31 to 40. 42. The recreational vehicle of claim 41, further comprising wheels that enable traction of the recreational vehicle.

Images